7 -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
 Spare parts catalogue
Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Removal of the airbox
Detach the oil breather pipe (2) and the stepper motor tube (20) by slackening ties (1) and (5).
In the ABS version loosen the screws (31), to remove the hose guide (3) and collect the spacers (4).
Detach the tabs (B) and release the drain hose (12) from the cover (A) on the generator cover (Sect. 9 - 8, Removal of the generator cover).
Disconnect the cables (C) of horizontal cylinder coil (D) and the vertical cylinder coil (E) from the respective spark plugs.
Disconnect the coil connectors (F) from main wiring harness (Sect. 6 - 1, Routing of wiring on frame).
Loosen the clamps (G) of the couplings (H).
 
Undo the screws (16), recover the spacers (17) and withdraw the airbox vertically upwards, taking care to recover the rubbers (19).
Disassembly of the airbox
Loosen the hose clamps (11) and (1) and remove the drain hose (12) and the oil breather hose (2) from the airbox.
Remove the following electrical components
A
B
C
D
Coils (Sect. 6 - 12, Coil).
Note
Remove the air filter as described in Sect. 4 - 3, Changing and cleaning the air filters.
Reassembly of the airbox
Check the presence of the rubber block (19) on the airbox.
If removed, fit clamp (1) onto drain hose (2).
Install the drain hose (2) to the airbox, and set it so as hose slot (A) corresponds to arrow (B) on airbox.
For the remaining reassembly operations, reassemble following the removal procedure in the reverse sequence, and route wiring as shown in Sect. 6 - 1, Routing of wiring on frame.
Removal of the oil breather valve
Undo the screw (13) and remove the oil breather valve (14) from the crankcase half.
Check the condition of O-rings (15) and renew them if necessary.
Refitting the oil breather valve
Lubricate the two O-rings (15) with engine oil.
Install the oil breather valve (14) in the hole on clutch-side casing aligning valve hole (L) with threaded hole (H) on casing and starting screw (13).
Tighten the screw (13) to a torque of 10 Nm (Min 9 Nm - Max 11 Nm) (Sect. 3 - 3, Frame torque settings).
Refitting the airbox
Check that the rubber bushes (19) are present on the airbox.
Check that clamps (G) are correctly positioned on intake manifolds (H), with the fixing screws oriented as shown in the figure.
Locate the airbox assembly on the throttle body.
Fit and tighten the screws (16) with spacers (17) on the airbox, to a torque of 10 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Tighten the clamps (G) of the couplings to a torque of 1.5 Nm ±10% (Sect. 3 - 3, Frame torque settings).
 
Connect the cables (C) of horizontal cylinder coil (D) and the vertical cylinder coil (E) from the respective spark plugs.
Connect the coil connectors (F) from main wiring harness (Sect. 6 - 1, Routing of wiring on frame).
In the ABS version refit the hose clip (3) to the vertical cylinder head cover and start the screws (31) in their thread with the spacers (4).
Tighten the screws (31) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm) (Sect.  3 - 3, Frame torque settings).
Place the oil breather hose (2) and the stepper motor tube (20) and tighten the clamp (1) and (5) to a torque of 1.5 Nm ±10% (Sect. 3 - 3, Frame torque settings).
Fasten the drain hose (12) to frame using the clamps and under cover (A) on generator cover (Sect. 9 - 8, Refitting the generator cover) then engage retainers (B).
 
Positioning of the blow-by hose
Positioning of the airbox drain hose